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PCDIndustrial Tools Department
TOOLS
MAK. HIRD. SAN. TİC. LTD. ŞTİ.AKİFSAN
ANKARA BAYİİAKİFSAN MAK. HIRD. LTD. ŞTİ.İVEDİK ORG. SAN. 1445 SOKAK NO:32ANKARA-TURKEY T. +90 (312) 395 1 601 E. [email protected] / www.akifsan.com
PCD Milling Cutter ...................................... Aero Mill Series • Aero Mill Mini
• Aero Mill • Aero Mill Plus • KMP
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06
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16
34
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Contents
KORLOY’s PCD Reamer guarantees excellent surface finish and high accuracy for economical machining
PCD Reamers
KORLOY PCD Endmills guarantee long tool life and high productivity by shortening overall cycle time with diamond edge application
PCD Endmills
KORLOY PCD insert blades perform their best on aluminum alloy and non-ferrous metals resulting high efficiency and high quality
PCD Insert/Blade
PCD Product DescriptionsKORLOY PCD tools feature extremely high hardness and outstanding wear resistance thanks to their material technology combining a strict control of diamond crystals size, and a manufacturing process realized at ultra high temperature and pressure levels. KORLOY PCD tools answer the wide demand for machining aluminum alloy and non ferrous metals in the automotive and aerospace industry, while delivering an exceptional increase in productivity and precision.
PCD TOOLSProduct descriptions
04
KORLOY PCD Forming Tools is the solution to today’s increased complexity of workpieces’ shapes, while shortening cycle time
PCD Forming Tools
KORLOY PCD Boring Tools enlarges holes with high precision and presents an excellent quality of finishing
PCD Boring Tools
KORLOY PDC Milling Cutter, Aero Mill features accurateand economical face milling with adjustable blade height
PCD Milling Cutter
KORLOY PCD drill guarantees excellent cutting performance and tool life in aluminum alloy machining with full or partial diamond application on the tip
PCD Drills
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Technical DataPCD products are manufactured by binding poly-crystalline diamond in high density through super high pressure process, which enables an extremely high wear resistance.
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PCD TOOLSTechnical data
Aluminum alloy
Graphite
Si -Aluminum alloyCopper alloys
Wood,Stone
CeramicCarbon
Rubber
Material Polycrystalline diamond = Particle sintered diamond
Structure [Diamond crystal grain + diamond additive (metal, ceramic)] Sintering with high temperature and pressure (1200℃ , 50k atm)
Specification ⑴ Rough particle => High density and high heat conductivity - Good wear resistance, but low surface roughness
⑵ Low oxidation temperature. Drawing oxidation can happen for hard material processing
⑶ Fine particle => Excellent resistance to wear and chipping for general cutting
⑷ Ultra fine particle => Excellent surface finish and chipping resistance
PCD tools provide wide machining applicability and exceptional product performance
rough particle
Fine
Ultra-fine
Small
Large
Grain size
07
● PCD tool technical manual
● Hardness and strength of PCD
● PCD form
TRS
PCD 50(Gpa)
cBN23(Gpa)
Carbide alloy
17(Gpa)
TRS (Transverse Rupture Strength)
* TRS Flexural strength, or material property defining the degree of ductility or brittleness
HeatConductivity
PCD 560(W/m.k)
cBN200(W/m.k)
110(W/m.k)
Heat conductivity (Heat conduction)
* Thermal conductivity Material property to conduct heat
Hardness[High]
Strength, toughness [High][Low]
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PCD
cBN
Ceramic
CermetCoated
carbide alloy
Carbide alloy
HSS
TNMX CCMT SPGN
Carbide alloy
Grade Feature Use Grain size(㎛) Grain Hardness
(Hv)Transverse
rupture strength(kgf/㎟)
DP90
Material with rough diamond particle sintered. High percentage of diamond and excellent wear resistance
Processing of high-Si AI alloy, AI compound material, carbide alloy, ceramic semi-sintered compound and rough machining of embossed product. Processing of ceramic sintered coumpound, stone and rock.
Over25
10,000~
12,000110
DP150
Fine diamond sintered material. Same grain size of diamond and good coherence which enable processing effectiveness and wear resistance
Rough machining of non ferrous metal, and processing of carbide alloy, ceramic sintered compound, embossed products rough machining. Face processing and cutting of FRP, hard rubber, graphite, wood and mineral board.
1010,000
~12,000
200
DP200
Ultra fine diamond grain sintered material. Good sharpness of blade and toughness
Rough machining of non ferrous metal, carbide alloy, ceramic sintered compound, embossing product. Cutting and face processing of FRP, hard rubber, graphite, wood and mineral board.
0.58,000
~10,000
220
Work piece Cutting speed Feed 1 time cutting depth
Recommending material
1st time 2nd time
Aluminum alloy (4%~8%Si) 1,000 ~ 3,000 0.1 ~ 0.6
~ 3
DP150 DP200
Aluminum alloy (9%~14%Si) 600 ~ 2,500 0.1 ~ 0.5
Aluminum alloy (15%~18%Si) 300 ~ 700 0.1 ~ 0.4
Copper alloy~ 1,000
0.05 ~ 0.2
Tempered plastic 0.1 ~ 0.3 ~ 2
Wood material ~ 4,000 0.1 ~ 0.4 -
Carbide 10 ~ 30 ~ 0.2 ~ 0.5 DP90 DP150
Category PCD cBN
Thermalstability
Under common air condition Oxidation from 700℃ Stable up to 1300℃
Under vacuum condition Stable up to 1400℃ Stable up to 1500℃
Use Non ferrous metal, glass fiber,wood, hard plastic Heat treated iron, hard material
● PCD material
● Recommending cutting condition
● Comparison between cBN and PCD
09
10
Clea
ranc
e an
gle w
ear w
idth
0.05
0.10
10 20 30 400Cutting length(km)
Competitor ADP150
DP90
Competitor B
Clea
ranc
e an
gle w
ear w
idth
0.05
0.10
1 2 3 40Cutting length(km)
DP90
Competitor
DP150
Clea
ranc
e an
gle w
ear w
idth
0.1
0.2
Grade
vc = 800m/min fn = 0.1mm/rev ap = 0.2mm, Dry
Designation : SPGN120304Holder : FP11R
Continuous cutting test(Work piece : Al-25%Si)
vc = 350m/min fn = 0.2mm/rev ap = 0.18mm, Dry
Designation : CNMX120408Holder : PCLNL2525
Interrupted cutting test(Work piece : Al-20%Si)
vc = 15m/min fn = 3.7mm/rev ap = 0.5mm, Dry
Designation : SPGN120304Holder : FP11R
Continuous cutting test(Work piece : Al-25%Si)
● Cutting test case
DP90 Competitor
- Shorten the processing time with excellent chip elimination rate, and enhanced productivity
- Make the chip stable under high speed and high carry processing for stable process
- Enhance product quality and lower the defective ratio with excellent surface roughness and tolerance of dimension.
- With exclusive 3 dimensional chip breaker design, cutting resistance and strength of cutting blade are enhanced, which extend tool life
NM
NF
1.2
1.0
0.7
0.5
0.2
0.05 0.07 0.10 0.12 0.15
ap (m
m)
fn (mm/rev)
3.0
1.5
1.0
0.8
0.5
ap (m
m)
0.10 0.15 0.20 0.25 0.30fn (mm/rev)
NM NF
● Chip breaker insert
● Chip processing area
● Chip discharge result
11
ap (m
m)
3.0
2.5
2.0
1.5
1.0
0.5
0.25
NM
NF
0.05 0.10 0.15 0.20 0.30 0.35fn (mm/rev)
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Insert / BladeWide machining applicability covers turning and milling on aluminum alloy and non-ferrous metals. High hardness of PCD insert/blade results in excellent wear resistance, high precision and high efficiency.
PCD TOOLSInsert / Blade
Type DesignationGrade Dimensions (mm)
Applicable HolderDP90 DP150 DP200 Inscribed circle Thickness Nose R Hole size
- Milling tool for finishing aluminum alloy with an adjustable cutting height- PCD and carbide inserts available- Chip cover design for higher durability and better chip evacuation.- Cutter body made of aluminum alloy for high speed machining- Balance level reachable with a balancing screw : G2.5
- Availability of PCD as well as carbide inserts- Maximum adjustment range ±0.1mm, in 2㎛ as a fine control unit- Through coolant system- Simplified cutter structure- Wide chip pocket area for aluminum alloy finishing and roughing- Balance level reachable with a balancing screw : G2.5
- Blade type simple cutter geometry without a chip cover enabling diverse number of cutting edges- Direct coolant injection onto the blade increasing tool life- Simple clamping system with a spanner adjustment system improving fine control(1㎛) and shortening setting time by 50%, compared to existing 5 edges type cutters- Exclusive lightweight coolant bolts reducing the cutter weight by 30%, compared to existing Ø125 cutters
Specification
Cutter diameter
Applicable inserts
Structure
Through coolant
Application
Max. rpm
Ø32 ~ Ø63
PCD and carbide inserts
Steel bodyand inserts
Direct injectiononto the edge
Roughing and finishing
26,000 (for Ø32)
Ø80 ~ Ø315
PCD and carbide inserts
Aluminum bodyand inserts
Aluminum bodyand blades
Central injection
Roughing and finishing
16,000 (for Ø80)
Ø80 ~ Ø315
PCD blades
Direct injectiononto the edge
Medium cutting to finishing
16,000 (for Ø80)
Aero Mill Mini Aero Mill Aero Mill Plus
● Aero Mill
● Aero Mill mini
● Aero Mill plus
Aero Mill
Diameter(mm) Type Designation Shape Note
Ø80
CoolantBolt
CBP080-IN/MM
Extracharge
Ø100CBP100-IN
CBP100-MM-1
Ø125CBP125-IN
CBP125-MM-1
Ø160CBP160-IN
CBP160-MM
Ø200Coolant Cover
CCP200
Ø250 CCP250
Ø315 CCP315
0.03
~0.0
5
0.03
~0.0
5
0.2TungstenCarbide Insert
PCD Insert
0.03
~0.0
5
0.03
~0.0
5
0.2PCD FacingInsert
PCD WiperInsert
Tungsten Carbide, PCD Insert
PCD Facing, PCD Wiper Insert
Aero Mill Approachangle 90°
Insert reliefangle
Number of tooth6:6 teeth
Tool diameterISO : mmAISI : inch
A : Cartridge + Insert type
Arbor typeA : Inch M : Metric
Hand of toolR : Right L : Left
6ZA P A-D (M) 100 R
● Code System
● Coolant parts
Dept
h of
cut,
ap (m
m)
Feed, fz(mm/t)
6.0
5.0
4.0
3.0
2.0
1.0
0.05 0.1 0.15 0.2 0.3
Aluminum alloy
Cuttin
g Sp
eed
(m/m
m)
Feed, fz(mm/t)
5000
4000
3000
2000
1000
500
0.1 0.2 0.3
Aluminum alloySiunder 13% (H01, PCD)
Aluminum alloySi over 13%(PCD)
● Application range ● Recommended cutting condition
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❶ Insert
❺ Cutter
❼ Insert Screw
❻ Cutter Seat
❹ Adjust Screw❸ Cartridge Screw
❷ Cartridge
1. Place ④Adjust screw in ⑥Cutter Seat2. Insert ②Cartridge to ④Adjust screw in ⑥Cutter Seat3. Insert ③Cartridge screw and joint right direction by 10Nm4. Place Insert on the Cartridge and joint them together by 5Nm5. Disassembly is performed in reverse order of the assembly
1. Please use OHP film to protect PCD insert and blade when you adjust tolerance.It can cause chipping during adjusting run-out
2. Please rotate the adjust screw to right direction only. When you exceed zero tolerance, should release cartridge screw first and rotate adjust screw to left direction, then rotate it to right and adjust again
1. Clean the measuring instrument and set the position of the Aero mill cutter2. Release ③Cartridge screw first, then joint slightly by 2Nm3. Rotate the ④Adjust screw right direction and adjust it up to 5㎛ (dial gage)4. Joint ③Cartridge screw tightly by 10Nm5. Adjust it to the zero tolerance by rotating ④Adjust screw to the right direction※ When you rotate ④Adjust screw to the right direction, inserts move to upper direction
● Application range ● Coolant bolt — sold separately
● Recommended cutting condition
Aero Mill Mini
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1. Please be advised that chipping can be caused on cutting edges when using the dial gauge to adjust mounted inserts. It is highly recommended to using a piece of protective films like cellophane paper or OHP.
2. The maximum adjustment should be made within ±0.1. Too much adjusting might damage ②Insert Screws.
3. ②Insert Screws are prone to be damaged by stress concentration. Please replace them with new ones every six month.
1. Make air blows onto measuring apparatus and ⑥Cutter Seats to remove dust2. Use an HW20L wrench to make ③Adjust Screws be close to the bottom. After that, mount individual ①Insert on each ⑥Cutter Seat, tightening an adjacent ②Insert Screw in torque of 2Nm.3. Tight the ③Adjust Screws clockwise to reach the first numerical target. — The final target should be between -2㎛ and -3㎛. 4. Following reaching the first numerical target, completely clamp ②Insert Screws in torque of 5Nm.5. Tight the ③Adjust Screws clockwise to reach the final numerical target of between -2㎛ and -3㎛.※ Inserts might be floating when turning the adjust screw clockwise
6. In case of exceeding the final numerical target, repeat this process from No.2. Otherwise certain changes on cutting edges could be caused.
How to adjust run-out of the Aero mill mini
● Assembly structure of cutter
1. Use an HW20L wrench at a ⑥Cutter Seat so that the bottom part of an ③Adjust Screw should be very close to the cutter body
2. After clamping the ③Adjust Screw, mount an ①Insert on the ⑥Cutter Seat, tightening the adjacent ②Insert Screw. Repeat this with remaining inserts.
Diameter(mm) Type inch / mm Designation Shape Material Note
Ø80
Coolantbolt
inch, mm CB12-AMP80
Steel Included
Ø100inch CB16-AMP100mm CB16-AMP100M
Ø125inch CB20-AMP125mm CB20-AMP125M
Ø160inch CB24-AMP160mm CB20-AMP125M
Ø200Coolantcover inch, mm
CCV-AMP200Aluminum Extra
chargeØ250 CCV-AMP250Ø315 CCV-AMP315
● Code System
● Coolant parts
Aero Mill Plus
Aluminum alloy
Dept
h of
cut
, ap
(mm
)
Feed, fz (mm/t)
6.0
5.0
4.0
3.0
2.0
1.0
0.05 0.1 0.15 0.2 0.3
Cuttin
g sp
eed,
vc (m
/min)
Feed, fz (mm/t)
5000
4000
3000
2000
1000
500
0.1 0.2 0.3
Aluminum alloySi 13% less
Aluminum alloySi over 13%
● Application range ● Recommended cutting speed
Diameter (mm) Max. revolution (rpm)
Ø80 20,000
Ø100 18,000
Ø125 16,000
Ø160 13,000
Diameter (mm) Max. revolution (rpm)
Ø200 10,000
Ø250 8,000
Ø315 7,000
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● Max. RPM
1. Clean the measuring instrument and set the position of the Aero-Mill cutter2. Release ③Blade screw first, then joint slightly by 2Nm3. Rotate the ④Adjust screw right direction and adjust it up to -20μ (dial gage)4. Joint ③Blade screw tightly by 10Nm5. Adjust it to the zero tolerance by rotating ④Adjust screw to the right direction※ When you rotate ④Adjust screw to the right direction, blades move to upper direction
How to Adjust the Run-out on the Aero Mill Plus
● Assembly structure of cutter
1. Place ④Adjust screw in ⑥Cutter Seat
2. Insert ②Blade to ④Adjust screw in ⑥Cutter Seat (Fasten vertically, since screwing horizontally is not possible)
3. Place ④Adjust screw in ⑥Cutter Seat4. Disassembly is performed in reverse order of the assembly
●How to Assemble the Aero Mill Plus
1. Please use OHP film to protect PCD blade when you adjust tolerance. It can cause chipping during adjusting run-out
2. Please rotate the adjust screw to right direction only. When you exceed zero tolerance, should release cartridge screw first and rotate adjust screw to left direction, then rotate it to right and adjust again
1. The lightweight body of aluminum alloy keeps the main spindle from having overload in high speed machining.
2. The cutter specifically designed for PCD blades has now increased number of corners. Special aluminum alloy of which material property has high toughness was employed to provide strong cutting performance.
3. Wide chip pocket areas are applicable for finishing or roughing aluminum alloy.
4. Cutter damage problem has been solved by the use of chip covers in high speed machining.
EndmillKORLOY PCD Endmills guarantee long tool life andhigh productivity by shortening overall cycle time withdiamond edge application
PCD TOOLSEndmill
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• High rake angle insert reducing burr creation• High speed and high efficiency machining• Improved surface finish• Ideally suited for finishing non ferrous metals and machining reinforced plastics
DrillKORLOY PCD drill guarantees excellent cuttingperformance and tool life in aluminum alloy machiningwith full or partial diamond application on the tip
PCD TOOLSDrill
• Improved surface roughness and hole tolerance• High precision hole making tool ideally suited for aerospace components or composite materials• Hole making capability complying with the demanding IT tolerance level 7~8• Longer tool life and higher productivity• Stepped drill design for a sharp cut with lower cycle time
ReamerKORLOY’s PCD Reamer guarantees excellent surface finish and high accuracy for economical machining
PCD TOOLSReamer
• Using PCD tools significantly improves tool life (10 times longer than the carbide type)• Excellent surface finish and high accuracy with small margins of error• High cutting angle shortens cutting time and increases productivity• Custom tools provided in various forms according to our customers’ cutting environment• Multi-stage geometry integrated with copying form enables the possibility of machining multiple holes at once• Ability to produce clean unburned surfaces at cutting speeds over 300m/min• Stable machining even with water-soluble emulsion type cutting fluid
Specifications
Cutting speed, vc(m/min)
Feed rate, fn(mm/rev)
Diameter increase(mm/hole)
Cutting fluid
120
0.2
0.4
Water-soluble
120
0.2
0.4
Oil
Surface roughness (Rz)
Roundness
3
5
8
10
PCD Reamer Carbide Reamer
exellent
exellent
38
PDR
Work piece vc(m/min) fz(mm/t)
Aluminum Alloy 50 ~ 250 0.05 ~ 0.20
Diameter(Ø):070 :Ø70
PCD Reamer No. of Flute
PDR 2 032
(mm)
Designation ØD Ød ℓ L
PDR 2050 2 5.0 6.0 30 65
2060 2 6.0 6.0 40 75
2070 2 7.0 8.0 40 75
2080 2 8.0 8.0 40 75
2090 2 9.0 10.0 40 85
2100 2 10.0 10.0 40 85
2120 2 12.0 12.0 50 95
2140 2 14.0 16.0 50 95
2150 2 15.0 16.0 50 100
4160 4 16.0 16.0 50 100
4180 4 18.0 20.0 60 110
4200 4 20.0 20.0 60 110
● Code System
● Recommended Cutting Condition
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Forming ToolKORLOY PCD Forming Tools are the solution to today’s increased complexity of workpieces’ shapes, while shortening cycle time
Mono ToolKORLOY PCD Mono Tools are ideal for high precision machining due to its structure with integrated arbors
PCD TOOLSForm Cutter
• Increased productivity due to long tool life and excellent surface finish• Shortens cycle time using complex forms combining copying and multi-stage design
• Standard through coolant type• Good performance in roughing as well as finishing• Balance level : G2.5• Surface roughness(Rz) : 3~25㎛
SawKORLOY PCD Saw is ideal for high speed and high precision machining of non-ferrous metal — a metal, including alloys, that does not contain iron (ferrite) in appreciable amounts, such as copper, aluminum, magnesium, etc.